Brad Herbert, ON Semiconductor. Alan Knapp, Siemens Industry, Inc. Water Technologies. Wayne Bates, Hydranautics. John Morgan, H2Morgan LLC

Transcription

1 Brad Herbert, ON Semiconductor Alan Knapp, Siemens Industry, Inc Water Technologies Wayne Bates, Hydranautics John Morgan, H2Morgan LLC Presented By: A Knapp

2 In the past the economics of doing Reverse Osmosis (RO) reject recovery had not often penciled out to be economically favorable for most water plants This presentation will provide an outline of the methodology & tools to help determine if there is an economical favorable benefit of RO Reject Recovery; in addition to enhancing environmental sustainability and green corporate citizenship Content: - RO Recovery Past and Present - RO Membrane Technology development - Antiscalant and Monitoring Improvements - ROI and Economic Benefits - Financing Models - The Final Solution - Conclusions CPA5-LD RO Element CPA5 Page 2

3 What do we mean by Processing RO Reject with Additional RO for Additional Water Recovery Typical UPW Makeup Water Process City water Chem Feed Filtration Makeup RO RO Product to DI Antiscalant Makeup RO Reject Brine Recovery RO RO Reject (Brine) Additional RO Product to Makeup Waste Water to Drain RO Reject Reduced Waste Water to Drain Page 3

4 Historical Roadblocks and Today Past Low cost of municipal hook up and allocation fees for water and Sewer Less robust techniques manage the water chemistry challenges of a RO Treatment system Higher capital costs for treatment systems, membrane and materials Previous generations of reverse osmosis membranes required much higher Pressure Energy to operate Limited Financing Opportunities Existing city infrastructure and capacity not critical Water conservation and environment sustainability were not a focus of Corporations Present RO Membrane Technology, Efficiency and Performance improvements Pretreatment technology improvements Increasing utility costs (Water, sewer, electricity, etc) Site utility infrastructure surcharge for increased water and sewer usage due to expansions Flexible financing options for implementation Corporations have made water conservation a priority Page 4

5 Advances in RO Performance Improved membrane chemistry for increased flux and rejection, selective ion rejection, lower fouling, and enhanced durability Anti-Telescoping Device (ATD) for increased flux and rejection, selective ion rejection, lower fouling, and enhanced durability Feed Brine Spacer modified to reduce pressure losses and improve cleanings Permeate Carrier design improvements to reduce potential for membrane embossing and increase in element efficiency Larger Diameter Elements for overall system cost reduction Page 5 Membrane Leaves optimize number of leaves per element and leaf length to increase efficiency Automated manufacturing for increased membrane area and a more consistent product

6 Advances in RO Membrane Performance Decade Type Area (Sq Ft) 1970 Cellulose Acetate 1980 Thin Film Polyamid e 1990 Thin Film Polyamid e Flow GPD (at 225 psi) NaCl Rejectio n Feed Spacer (mil) % % % LD 34-mil Biostatic Feed Spacer Thin Film Polyamid e 2000 Thin Film Polyamid e % % Delta-Pressure of 1st stage (bar) CIP CIP CIP CIP CIP CIP 28 mil 31 mil 34 mil 2010 Thin Film Polyamid e Page % 34 Biostatic History of Highest Rejection Brackish Water RO Elements Operation Period (days) CIP Cleaning Frequency from Colloidal Fouling

7 Advancements in Antiscalant/Dispersants Early applications included inorganic SHMP (sodium hexametaphosphate) used to control sulfate scales 1980 s saw synthetic polymers of polyphosphanates and polyacrylates compatible with RO membranes developed which were also good for CaCO3 control and allowed for better recovery Blending of phospanates with polyacrylates resulted in better antiscalants/dispersants for control of: CaCO3 scaling Ba, Sr, Ca Sulfate scaling Silica fouling Iron fouling Colloidal fouling To increase recovery, new antiscalant/dispersants are now being invented from biotechnology & coating industries using hyper branched polymers like dendrimers Page 7

8 The Dashboard Advances in the automation technology to retrieve and chart real time data give operations high confidence to push systems harder and quickly react and correct trends that may cause system excursions or potential downtime Flow (GPM) Brine RO Product Flow 30 Days Data Frequency 5 Min /6 7/11 7/16 7/21 7/26 7/31 8/5 8/10 8/15 Flow (GPM) Brine RO Reject Flow 30 Days Data Frequency 5 Min /6 7/11 7/16 7/21 7/26 7/31 8/5 8/10 8/15 Salt % Rejection Brine RO % Salt Rejection 30 Days Data Frequency 5 Min /6 7/11 7/16 7/21 7/26 7/31 8/5 8/10 8/15 Flow (GPM) Brine RO Feed Flow 30 Days Data Frequency 5 Min /6 7/11 7/16 7/21 7/26 7/31 8/5 8/10 8/15 % RO Recovery Brine RO % Recovery 30 Days Data Frequency 5 Min /6 7/11 7/16 7/21 7/26 7/31 8/5 8/10 8/15 Brine RO Dashboard H2Morgan "Ctrl Alt F5" to Refresh Page 8

9 ROI and Water Rates Energy Costs Relatively Flat Triggers For Sites to investigate RO Reject Recovery: Running close to purchased discharge Capacity Needed more capacity to add Wet Benches Page 9 Options: Reduce water use however optimizing Tool Sets did not conserve enough water Purchase additional capacity with city Pay exceedance fees; Surcharge

10 What is Financing? Support customers with new technology, capital improvements and water saving initiatives by providing innovative, flexible, competitive financing solutions combined with services $1 Purchase Option (Capital Lease) Title is held by Lessor and passes to Lessee at end of term $100 Purchase Option or Stipulated Purchase Amount (10%) Loan Customer holds title and receives tax benefits of ownership Treated as a capital acquisition by customer A means to get away from the traditional capital purchase Free up capital $$ for other things Fair Market Value (True Lease) Available on a case by case basis Customer has option to renew, return, or purchase equipment at end of term Page 10

11 On Semiconductor water savings using a Reverse Osmosis system for reject water Problem: Needed additional capacity without using more city water Traditional capital $$$$ purchase not budgeted for and 18 month ROI Siemens Industry WT provides: BRRO Reverse Osmosis Integrated System Equipment: $$$$ Siemens Financial Services provides: Capital Lease (includes standard equipment and commissioning) 2 year lease for $$$/month Customer Benefits: Reduction of water to drain, water savings $$ Immediate water savings with No Upfront Investment Immediate realized savings $/month, ROI! Additional Benefits: Convenience Improve cash forecasting and budgeting Conserve credit lines 100% financing Flexibility Page 11

12 Simplified Flow Diagram of the Process Existing RO Reject Inlet Storage 1000 gal M 83 3:2:1 Array 50% recovery RO Product back to UPW System Overflow 1000 gal Reject To Waste Page 12

13 Brine Recovery RO Operation: Day 0 Actual Day 0 Projected Day 135 Actual Day 135 Projected Feed pressure 108 psi 129 psi 136 psi 118 psi Delta P 23 psid 25 psid 57 psid 29 psid Feed TDS 149 ppm 149 ppm 424 ppm 424 ppm Feed TOC 144 ppm 22 ppm Permeate TOC 002 ppm Permeate us 12 us 26 us 40 us 60 us Permeate SiO2 012 ppm 014 ppm 025 ppm Salt rejection 997% 994% 997% 995% Silica rejection 996% 997% 996% TOC rejection 994% Some fouling exists but is controlled and manageable Fouling is colloidal and organic in nature Currently cleaning about every 6 months, (3-4 month element cleaning was expected) 1st element change out after 5 months 2nd element change out due after 7 months Normalized % salt rejection is stable Normalized permeate flow is relatively stable Delta P increases steadily over an extended period of time Page 13

14 Conclusions: Brine recovery on existing Makeup equipment using additional RO membrane treatment is now a viable and economical return on investment for most Industrial Water Treatment Facilities Better Technology -Membrane -Antiscalant -Monitoring Water and Energy Costs Financing Options Sustainability Credits Page 14

15 Authors: John Morgan of H2Morgan Engineering: Mr Morgan is a 16 year veteran of Semiconductor UPW/Waste Water Engineering, Facilities Operations He is the Principle Chemical Engineer for H2Morgan Engineering He has worked at Semiconductor FABs in Oregon, Israel, and Ireland Before working in the Semiconductor Industry, Mr Morgan spent 11 years in Defense Manufacturing working in Industrial Waste Water treatment, Ground Water remediation, and Maintenance Supervision He holds a Bachelor of Science in Chemical Engineering from the University of Arizona He can be reached at JohnMorgan@H2Morgancom Brad Herbert of ON Semiconductor: Mr Herbert has over 19 years experience in Water Treatment and has been in the Semiconductor Industry for 17 years He is currently a Facilities Engineer at ON Semiconductor in Gresham, Oregon Mr Herbert has worked for AMD, IDC (CH2MHill), and ELTECH (water treatment OEM) He holds a Bachelor of Science in Chemical Engineering from the University of Missouri Alan Knapp of Siemens Industry Inc Water Technologies: Mr Knapp is the Marketing Director; Semiconductor and Solar for Siemens Industry, Water Technologies Alan has been active with industrial water, solutions and products, since 1984 including power and pharmaceutical markets, with a focus on semiconductor applications since 1995 Additional papers include Ultrapure Water Magazine; "Critical Ultrapure Water Applications for the Semiconductor Industry" and studied Mechanical Engineering at Conestoga College He can be reached at or at alanknapp@siemenscom Wayne Bates of Hydranautics: Mr Bates has 32 years of experience in the engineering, trouble-shooting, design, project management, sales and marketing of water treatment membrane systems for brackish water, sea water and waste water applications in both the industrial and municipal water markets He has authored 27 papers on RO and UF membrane technology and has participated in training seminars around the world He rejoined Hydranautics/Nitto Denko for a second tour as an Engineer in the Membrane Technology Department in 2007 Prior to this, he served four years with Carollo Engineers, 10 years with Hydranautics as a regional accounts manager and technical manager, and 15 years at Illinois Water Treatment which later became US Filter and Siemens He has a bachelor s degree in chemistry from Illinois Wesleyan University and is a member of the American Water Works Association, the International Desalination Association, the American Membrane Technology Association, and the Southeast Desalting Association QUESTIONS? Page 15